Flexible flat cable

ABSTRACT

A flexible flat cable includes at least two layers of nonwoven fabric, the fabric consisting of fibers selected from the group consisting of polyester, polyamide, polyolefin, syndiotactic polystyrene, polysulfone, and glass, the fabric having pores between the fibers, the flat cable also includes a first signal lead embedded between the at least two fibers and a binder disposed in the pores so as to provide the fabric with at least one of a dielectric strength of at least 500 V and a dimensional stability of at least 0.05% at a temperature of 140° C. over a period of 24 hours.

[0001] Priority is claimed to German Patent Application DE 102 27 890.3-34, filed Jun. 21, 2002, which is incorporated by reference herein.

BACKGROUND

[0002] The present invention relates to a flexible ribbon cable or other flexible flat cable which is composed of at least one signal lead embedded between at least two layers of nonwoven fabric.

[0003] U.S. Pat. No. 5,049,435, which is incorporated by reference herein, describes flexible printed circuit boards which are reinforced with nonwoven fabrics composed of polyaromatic amides, and which can be used as flat cables. To this end, the nonwoven fabrics composed of polyaromatic amides are impregnated with a heat-and/or light-curable resin.

[0004] Moreover, U.S. Pat. No. 5,744,756, which is incorporated by reference herein, describes a cable, which is insulated by meltblown microfibers.

SUMMARY OF THE INVENTION

[0005] An object of the present invention is to provide a flexible flat cable, which is easy and inexpensive to manufacture.

[0006] The present invention provides a flexible ribbon cable or other flexible flat cable which is composed of at least one signal lead embedded between at least two layers of nonwoven fabric which are manufactured only from fibers of polyester, polyamide, syndiotactic polystyrene, polysulfone and/or of glass and whose pores between the fibers or filamentes are filled with a binder to such an extent that a dielectric strength of at least 500 V and/or a dimensional stability of at least 0.05% at a temperature of 140° C. over a period of 24 hours are present. Surprisingly, the ribbon cables or other flat cables according to the present invention exhibit a dielectric strength and a dimensional stability according to industry requirements even without using polyaromatic amides.

[0007] Preferably, signal leads having different cross sections and/or made of different materials are present in the ribbon or other flat cables. These signal leads can be light and/or current conductors. The electrical signal leads advantageously have a thickness of 5 to 200μm and the distance from each other is equal to or greater than their thickness. Advantageously, the pitch of the signal leads with respect to each other is 1.25; 1.27; 2.5 or 2.54 mm.

[0008] Preferably, the ribbon cable or other flat cable according to the present invention contains flame retardants which are introduced either together with the binder or during the deposition of the nonwoven fabric.

[0009] Particularly preferably contained as the flame retardant are leather fibers which, in particular, are leather fiber residues from the production of chrome leather.

[0010] Moreover, the present invention relates to a method for manufacturing a flat cable, such as a ribbon cable, using nonwoven fabrics which have an air permeability of 20 to 8000 mm/s at a pressure differential of 200 Pa and between which at least one signal lead is inserted into a nonwoven fabric impregnated with a binder in such a manner that a dielectric strength of at least 500 V and/or a dimensional stability of at least 0.05% at a temperature of 140° C. over a period of 24 hours are achieved.

[0011] Advantageously, the binder is applied to the nonwoven fabric layers in liquid, powder or fibrous form or as a film prior to connecting the nonwoven fabric layers to the signal lead.

[0012] According to the present invention, thermoplastic polymers, such as polyolefins, polyesters, polyimides, polyamides, polyurethanes, polyacrylates, or nitrile butyl rubber, or crosslinkable systems, such as polyurethanes, epoxy resin systems, or UV-crosslinkable products, are used as the binder.

[0013] Particularly preferred is a method in which the nonwoven fabric layers are laminated together with the signal lead to form a composite and are subsequently impregnated with a binder. The ribbon or flat cable is brought into the completed state either by drying and/or by cross-linking the binder solution and/or dispersion.

[0014] The ribbon or flat cables are used for wiring in vehicles or in household electrical appliances.

BRIEF DESCRIPTION OF THE DRAWING

[0015] The present invention will be described with respect to a preferred embodiment, in which:

[0016]FIG. 1 shows a block diagram illustrating a method according to the present invention.

DETAILED DESCRIPTION

[0017] As shown in FIG. 1, a method for manufacturing a flat cable includes the step of providing a first and second layer of a nonwoven fabric. (See block 1). The nonwoven fabric has an air permeability of 20 to 8000 m/s at a pressure differential of 200 Pa. At least one signal lead is inserted between the first and second layers. (See Block 2). The nonwoven fabric is impregnated with a binder so as to provide a dielectric strength of at least 500 V and/or a dimensional stability of at least 0.05% at a temperature of 140° C. over a period of 24 hours. (See block 3).

[0018] In the following, the present invention will be explained in greater detail with reference to examples.

EXAMPLE 1

[0019] A flexible flat cable composed of two spunbonded polyethylene terephthalate nonwoven fabrics is manufactured in that the electrical signal leads having a thickness of 30 μm are laminated in between the spunbonded nonwoven fabrics at a distance of 2.5 mm from each other at 120° C. with the aid of an adhesive nonwoven fabric of copolyamide.

EXAMPLE 2

[0020] A flexible flat cable composed of two spunbonded polyethylene terephthalate nonwoven 

What is claimed is:
 1. A flexible flat cable comprising: at least two layers of nonwoven fabric, the fabric consisting of fibers selected from the group consisting of polyester, polyamide, polyolefin, syndiotactic polystyrene, polysulfone, and glass, the fabric having pores between the fibers; a first signal lead embedded between the at least two fibers; a binder disposed in the pores so as to provide the fabric with at least one of a dielectric strength of at least 500 V and a dimensional stability of at least 0.05% at a temperature of 140° C. over a period of 24 hours.
 2. The flat cable as recited in claim 1 wherein the flat cable is a ribbon cable.
 3. The flat cable as recited in claim 1 further comprising a second signal lead having a cross-section different from a cross-section of the first signal lead.
 4. The flat cable as recited in claim 1 further comprising a second signal lead made of a material different from a material of the first signal lead.
 5. The flat cable as recited in claim 1 wherein the first signal lead includes at least one of a light conductor and a current conductor.
 6. The flat cable as recited in claim 1 wherein the first signal lead is an electrical signal lead having a thickness of 5 μm to 200 μm and a length equal to or greater than the thickness.
 7. The flat cable as recited in claim 1 further comprising a second signal lead wherein the wherein the first and second signal leads are arranged at a pitch of 1.25, 1.27, 2.5, or 2.54 mm.
 8. The flat cable as recited in claim 1 further comprising at least one flame retardant.
 9. The flat cable as recited in claim 8 wherein the fabric includes leather fibers as the flame retardant.
 10. The flat cable as recited in claim 9 wherein leather fibers include residues from a production of chrome leather.
 11. A method for manufacturing a flat cable comprising: providing a first and second layer of a nonwoven fabric having an air permeability of 20 to 8000 m/s at a pressure differential of 200 Pa; inserting at least one signal lead between the first and second layers; impregnating the nonwoven fabric with a binder so as to provide at least one of a dielectric strength of at least 500 V and a dimensional stability of at least 0.05% at a temperature of 140° C. over a period of 24 hours.
 12. The method as recited in claim 11 wherein the impregnating includes applying the binder to the nonwoven fabric layers in one of a liquid form, a powder form and a fibrous form.
 13. The method as recited in claim 12 wherein the impregnating includes applying the binder the nonwoven fabric layers as a film prior to the inserting of the at least one signal lead.
 14. The method as recited in claim 13 the binder includes at least one of thermoplastic polyolefins, polyesters, polyimides, polyamides, polyacrylates, polyurethanes, and nitrile butyl rubber.
 15. The method as recited in claim 14 wherein the binder includes polymers able to be cross-linked with each other in a chemical reaction while supplying an energy.
 16. The method as recited in claim 15 wherein in the energy includes at least one of heat, UV radiation and electron bombardment.
 17. The method as recited in claim 16 wherein the energy initiates, maintains or promotes the chemical reaction.
 18. The method as recited in claim 11 further comprising laminating the fist and second layers and at least one signal lead together.
 19. The method as recited in claim 18 wherein the laminating is performed before the impregnating.
 20. The method as recited in claim 11 further comprising installing the flat cable as part of a wiring in a vehicle.
 21. The method as recited in claim 11 further comprising installing the flat cable as part of a wiring in a household appliance. 